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Medium-Duty Hydraulic Hybrids - A Best Use Scenario
CALSTART Webinar
June 20, 2013

2. History
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 Established in October 2008 with hydraulic hybrid concept
 Began development of a hydraulic hybrid system for
trucks and buses in April of 2009
 Currently on our 4th generation product, and entering
nationwide production this quarter
 Systems are sold through OEMs and bus and truck dealers
 Currently producing systems for Ford, GM, and
Freightliner, class 3-7
 Working under a joint development agreement with GM
since July 2011.

3. •Point 1
Hydraulic Hybrids
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The BRAKING
Energy pumps
hydraulic fluid from
the low pressure
tank to the high
pressure tank
This energy is
STORED in the
form of hydraulic
pressure in the
high pressure tank
Hydraulic pressure
drives the hydraulic
motors to provide
ACCELERATION

4. System Diagram
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Skid-based installation

6. Installation
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7. Skid-based installation
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8. Driver Interface Screen
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9. We Aren’t Done Yet!
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• Recently developed and tested a
Plug-In version that combines the best
of electrics (energy for gas-free driving) and hydraulics (best
brake regeneration solution) and
shows strong promise for unique drive-
cycle fleets
• Designing the next generations of systems, including a
Solid-State system that will replace the vehicle transmission.
Each generation is designed to reduce the price by 40%

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1. Better fuel economy
2. Ability to retrofit to existing vehicles
3. Support for Propane, CNG, gas, and diesel
4. Cleaner fleets and Green Marketing
LH’s Hydraulic Hybrids provide:

11. Clear Benefits
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 Dramatically better acceleration and fade-free braking
 ENERGY SAVINGS: 20-40% fuel mileage increase
in stop-and-go driving
 ENVIRONMENTAL IMPACT: 30% emissions decrease
 COST: 1 to 4 Year ROI
Based on fuel and brake savings alone
 Additional ROI potential
 Engine downsizing
 Government rebates
 Green Marketing
 OEM installation in 15 minutes
 Retrofit installed in 8 hours

12. How LH is different
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Shortest Financial Payback
Up to 40% improvement in fuel economy
gives fleets immediate operational savings
and a 1 to 4 year payback
(depending on drive cycle and fuel prices)
More Power
Lightning Torque Management provides low-
end torque (up to 700 ft/lbs) while advanced
controls provide a smooth drive with no
driver training required
Better Safety
Dramatically improves braking, providing
fade-free and faster stops with less pedal
pressure, while extending brake life 8 times
No Downtime
System runs parallel to the engine and
transmission so if the system is down the
vehicle drives and brakes like normal.
Diverse Fuel Hybridization
Works with gasoline, natural gas, propane
and diesel engines
Diverse Chassis Selection
Available today for
- Ford, Freightliner, GM
- 10,000 to 33,000 pound GVWR
- Delivery vans, buses, shuttle buses, utility
vehicles, cutaways, box trucks, etc.

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Medium Duty Fleet Work Trucks:
Perfect drive cycle for hydraulic hybrids
1. High miles driven = high fuel cost
2. Heavy Stop & Go drive cycle = frequent brake changes
3. Run by the numbers = every penny counts

14. CARB Testing
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• Currently undergoing testing for CARB certification –
completing paperwork and final baseline tests
• HVIP approval before the start of 2014 funding cycle

15. Real World Fleets and Feedback
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Vehicles Currently on-road:
• City of Loveland – Two 2012 Ford E-450 shuttle buses (StarTrans bus
bodies, Ford 6.8L V10 engine)
• Colorado State University – Two 2013 GM 4500 Box Vans (Supreme
bodies, (1) 4.8L V8, (1) 6.0L V8)
• National Fleet Hybrids (Boston) – One Ford E-350 paratransit
bus/demonstration vehicle 6.8L V10 engine
• Two LH test mules – One 2010 GM
4500 cutaway (6.0L V8), and one
Ford E-450 cutaway with 6.8L
• Currently building customer systems
for GM 4500 diesel platform, and 2
Freightliner chassis at a rate of 2/month

16. Real World Fleets and Feedback
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Fleet Feedback:
• Drivers initially comment on the brake pedal feel—but acclimate in about 1
hour
• Drivers appreciate the LH driver interface, have asked for a variety of
feature enhancements including competitive statistics with other drivers
• Drivers are able to run an entire route
braking only with the LH system--no
foundation brakes required.
• Drivers notice and comment on the
added acceleration
• LH System on/off switch means the vehicle
always runs, even when the LH system is down.
• LH System reliability has dramatically improved with each new customer vehicle—
but is not yet up to OEM standards.

17. System Modeling
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LH has a complete MatLab/Simulink model that consistently
models to within 2% of actual results for efficiency
Inputs:
- Drive Cycle
- Weight
- Engine efficiency map
- System parameters

18. Results: Modeling & Real-World Testing
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Drive Cycle is the most significant variable to efficiency improvements
range is 5-40% from brake regeneration (another 5% is possible from
start-stop technology, and another 30% from engine-downsizing)
LH system today is
~70% round trip
efficient
(electrics are ~20% on
same size vehicle)
Bottom line—if the
cycle doesn’t fit,
quit all hybrids

19. Getting to ROI
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• HVIP in California (and soon New York)
• Federal diesel (DERA) and transit (FTA) grants
• Clean Air grants from individual states
(Colorado, Texas, others)
• Lease financing
• $480/mo with $2,000 down
• Most fleets will save
$500 to $800/mo in
fuel and brake savings

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Tim Reeser
970-310-0135
Tim@LightningHybrids.com
www.LightningHybrids.com